NCE - Carbonevietnam.com.vncarbonevietnam.com.vn/pic/general/files/electrical...Vibration control Brush-holders pressure measurement, visual analysis and adaptation Complete machine

SE

RV

ICE

S &

MA

INT

EN

AN

CE

Mersen

Mersen is a Global expert in electrical specialties and graphite-

based materials.

Mersen has been working with major electrical rotating

machinery OEMs for more than 120 years, contributing to the

optimal performance of your equipment.

We provide high quality engineered solutions tailored to various

operating conditions, designed and tested for reliability and

optimum performance, such as carbon brushes, brush-holders,

slip ring assemblies, brush gear housing.

On the 5 continents our engineers and technicians provide

services, specific to the machines of each customer.

Your trustworthy partner

Worldwide network

Local presence

Approved and licensed technology

Highly qualified staff

Safety & Health qualifications:

Electrical works

Chemical environment

Working in height

Offshore

Mining

Specific customers’ safety authorizations

First aid / CPR

Complete risk assessment

• 2 / 23

Mersen’s solutions:

Brush wear, maintenance and downtime reduction

Machine performance increase

Evaluation of the equipment condition before total or partial repairs

All market segments

All types of machines

Replacement parts

Mersen: A complete range of Services

Training

R&D Expertise

Re-engineering

In Situ Machining

Diagnostics

DIAGNOSTICS

On-site motor inspections

Application

Mechanical

Electrical

Engineering / Environment

TRAINING

High quality technical training

Customized training curriculum

At either our location or yours

Technical seminars

RE- ENGINEERING

Design and re-engineering of components

Re-design

Complete retrofit solutions

IN SITU MACHINING

Machining and refurbishment of

your slip ring assemblies and

commutators

R&D EXPERTISE

Rental & development

of test benches

Material analysis

• 3 / 23

Mersen’s complete range of

Services

• 4 / 23

# Services & Training Description

1

On-site services -

Diagnostics

Standard machine inspection

2 Comprehensive inspection

3 Specific electrical machine

inspection

4 Machine environment inspection

5 On-site services –

In Situ Machining

In situ machining and

refurbishment of slip ring

assemblies and commutators

6 Re-engineering Design and re-engineering of

components

7 WindtrackerTM services offer

Complete service offer &

Technical expertise in signal and

power transfer

8

Training

At our location

9 At your location

10 Technical seminars

11

R&D expertise

Testing capabilities

12 Material analysis

1 → 4. On-site services – Diagnostics

• 5 / 23

MACHINE INSPECTION SPECIFIC

ELECTRICAL

INSPECTION

SPECIFIC

ENVIRONMENT

INSPECTION STANDARD

PACKAGE

COMPREHENSIVE

PACKAGE

Operating condition assessment

Carbon brush function and design analysis,

identification and choice of the grade

Slip ring assemblies and commutator film analysis

Commutator and slip ring assemblies: surface

roughness

Commutator geometry

Diameter measurement of commutators, slip ring

assemblies or rolling stock wheels

Vibration control

Brush-holders pressure measurement, visual

analysis and adaptation

Complete machine study

Carbon brush arm position equidistance control

Neutral line adjustment

Machine environment condition analysis

Evaluation of the heat exchange level

Temperature measurement of carbon brushes, slip

rings, commutator and winding

Commutation measurement

Measurement of the shaft and grounding current

Insulation measurement and control

Electric circuit control

Cooling flow calculation

Analysis of pollutants

Calculation of losses connected to the carbon brush

and commutator/slip ring assemblies

Technical report

1. On-site services – Diagnostics:


• 6 / 23

Description

1 Commutators and slip ring assemblies

Surface roughness

Commutator geometry

Vibration control (bearings, balancing, frame inspection, shaft alignment)

2 Brush-holders

Brush-holder pressure measurement

Brush-holder clearance to carbon brush measurement

Brush-holder condition visual analysis

3 Diameter measurement of commutators, slip ring assemblies and rolling stock wheels

4 Technical report


Vibration control Vibration analyser CL-Profiler DiaMeter


Technical issues:

Carbon brush dusting

High carbon brush wear

Sparking

Abnormal commutator or slip ring assemblies appearance (striation, deformation, electric marking etc)

Vibrations with fringed, cut, ripped off cables or glazed surface of carbon brush

Cable discoloration

Broken spring of the brush-holder

Slip ring threading

Selective action


Comprehensive inspection

• 7 / 23

Description

1 Static

Complete machine study (operating conditions, patina analysis)

Carbon brush arm position equidistance control

Neutral line adjustment

Carbon brush function analysis

Brush-holder adaptation

2 Dynamic

Environment conditions evaluation

Evaluation of the heat exchange level

Temperature measurement of carbon brushes, slip ring assemblies and commutator

Winding temperature measurement

Commutation measurement

Vibration control (shaft line)

Measurement of the shaft and grounding current

3 Technical report

Potential under brush reading


Technical issues:

Carbon brush dusting


Sparking



Cable discoloration


Flash over

Slip ring threading

Selective action


Specific electrical machine inspection

• 8 / 23

Description

1 Insulation: Rotating electrical machinery insulation measurement and control

Machine environment analysis

Winding temperature measurement

Insulation resistance

Capacity measurement in low and high frequency

Absorption current measurement

Polarization index

Discharge test

2 Electric circuit control

Ohmic resistance measurement

Impedance measurement

Capacity measurement

3 Technical report

Insulation control

with Megger measuring device Harmonics control

Measurement of

shaft currents


Technical issues:

Electrical marking on commutator strips, on slip ring assemblies or on the carbon brushes

Sparking

Vibrations

Turbo-alternator: current distribution problems

Specific electrical machine

inspection

LCR Meter


Machine environment inspection

• 9 / 23

Description

1 Temperature measurement at vent inlet and outlet

2 Cooling flow calculation

3 Analysis of pollutants

4 Calculation of losses connected to carbon brushes and commutator / slip ring assemblies design

5 General advice on components and materials (winding, insulation materials...)

6 Technical report

Control of the operating conditions

Thermometer

hygrometer Infrared camera


Technical issues:

High carbon brush or commutator wear

Oil presence in the carbon brush compartment

Coloration of the cable, brush-holder or commutator due to acid attack

5. On-site services – In Situ Machining:

In situ machining and refurbishment of

slip ring assemblies and commutators

• 10 / 23

Description

1 Diamond or ceramic machining of commutators and slip ring assemblies

2 Stone grinding of commutators and slip ring assemblies

3 Mica undercutting

4 Bar edge chamfering

5 Commutator and slip ring assemblies profile measurement

6 Commutator and slip ring assemblies diameter measurement

7 Replacement of the carbon brushes

8 Replacement and adjustment of brush-holders

9 Contact surface seating

10 Final dimensional inspection

11 Technical report


Technical issues:


Sparking



Cables coloration


Flash over

Slip rings threading

6. Re-engineering:

Design and re-engineering of

components

• 11 / 23

Re-design to reduce brush wear, maintenance and downtime

Complete retrofit solutions (carbon brushes, brush-holders, slip ring assemblies, brush gear housing)

Plug & play solutions

No machine modifications required


Description

1 Complete field diagnostic

2 Report to R&D

3 Analysis and recommendations

4 Prototype

5 Tests in the field (or test benches)

6 Tool design and manufacturing

7 Reengineered solution manufacturing

8 Follow up in the field and after sales

9 Technical report

Retrofit kit for Hitachi

generator

Technical issues:


Electromechanical failures

Old design electrical parts

Flash over

Slip rings threading

Over/under-loaded brush design

7. WindtrackerTM services offer:

Complete service offer & Technical

expertise in signal and power transfer

• 12 / 23

Description

1 Complete service offer:

Uptower support according to the industry’s safety standards

In situ machining of the generators’ slip ring assemblies

Training: Stagelec or Extelec

“Green” programs : dedicated carbon brush recycling program

2 Technical support & expertise in signal and power transfer:

Diagnostics

Re-engineering

Redesign to Cost

3 Offshore wind turbines Signal Transfer Systems maintenance service

4 Technical report


Technical issues:


Sparking

Abnormal slip ring assemblies appearance (striation, deformation, electric marking etc)


Cables coloration


Flash over

Slip rings threading or grooving

8 → 10. Training

• 13 / 23

Description

1

Introduction

Production of raw materials

Manufacture of carbon brushes and brush-holders

Brush grade groups and corresponding applications

2 Understanding the basic rules and functions of the carbon brush.

3 Parameters influencing the carbon brush behaviour

4 Analyzing motor malfunctions by observing the condition of the carbon brushes, commutators and slip ring assemblies

5 Using diagnostic and control equipment

6 Practical examples to improve preventive and corrective maintenance

Who should participate:

Engineers, technicians and electrical maintenance personnel

High quality Technical Training to help you to maximize the efficiency of your staff while minimizing the costs

With a variety of training solutions and highly qualified Mersen specialists, we can customize a learning solution that works for you

Customized Training Curriculum: dedicated program specially for your staff needs and experience level to optimize your time and learning

Training at customer’s site or in our Training facilities located in Europe, India and USA

• Duration: 2 days

• Session: as per time schedule

At our location

• Duration: according to request

• Session: on request

At your location

• Programme drawn up depending on your requirements

TECHNICAL SEMINARS

3 options:

OR

OR

11. R&D Expertise :


• 14 / 23

Description

1 Environmental chamber

to validate prototypes in all kinds of configurations:

Temperature: - 40°C / + 150°C

Humidity: 5% RH to 98%

Altitude: 0 to 2000 m = 790 mbar

Dimensions : (2.70 x 2.40 x 2.20 m / 9 x 8 x 7 ft)

2 Slip ring test bench

Speed: 0 to 2900 rpm

Maximum weight: 500 kg

Maximum current: 1200 A AC (according to the current density and number of carbon brushes)

3 Turbo generator test bench

Ring diameter: 19.0’’ (480 mm)

Ring grooves: 0.12’’ wide with 0.5’’ pitch

Ring material: 4140 Alloy steel

Ring peripheral speed: 0 to 100 m/s

Current density: 0 to 1200 A DC

Carbon brush dimensions: t x 25 x r mm (t x 1’’ x r)

4 Corrosion test bench

5 Development of new test benches

Support for new development projects

Support for electrical machines diagnostics

Large range of existing test benches

New test bench development

According to the customer’s specifications


Technical issues:

Development of electric machines for new applications

Application difficulties , extreme climate conditions, speed or current variations etc.

12. R&D Expertise:

Material analysis

• 15 / 23

Description

1 Carbon brush grades

Physico-chemical analysis

Micrographic structure

2 Metal products

Mechanical properties

Microstructure and chemical composition


In addition to other Mersen diagnostics

Support for new development project

Support for electrical machines diagnostics

Large variety of material analysis

According to the customer’s specifications

Comprehensive reports

Technical issues:

Inconsistent material performance

Incorrect grade selection

Brush safety: lead, other hazardous components

Services & Training: Main customer references

Railways: Indian Railways (India), Southern Rail (UK), ACTS (Netherlands), Goviathameslink (UK)

Transit transport: London Underground, Rotterdam metro, Athens metro, Transpole, Paris metro,

SNCF (France)

Ports & Marine: Jan de Nul (Belgium), Dredging (Belgium), ECT (Netherlands),

Igma Bulk Terminal (Netherlands) etc.

Training made for Metro of Istanbul (Turkey), Metro of Cairo (Egypt), RATP (France),

Metro of Singapore, Indian Railways, SNCF (France), ONCF (Morocco) etc. TR

AN

SP

OR

TA

TIO

N

Metallurgy: Arcelor Mittal (Belgium, France, Germany, Spain), Usiminas (Brazil), Tata Steel (Netherlands,

France) , Marcegaglia (Italy) etc.

Pulp & Paper: Shotton Paper (UK), SCA Hygiene (UK), Kappa (Netherlands),

Sappi (Netherlands, Belgium) etc.

Cement: Orcem (Netherlands), Holcim (Belgium), CBR (Belgium), Italcementi , Colacem (Italy)

Plastic & Rubber: Azko Nobel (Netherlands), Bayer (Belgium, Germany), AKG Polymers (Netherlands) etc.

Others: Eiffel Tower, Disneyland Paris (France)

Training made for Arcelor Mittal, Thales (France), ACOME (France), Georgia Pacific (France),

Vicat (France), Steel Authority of India, Jindal Steel (India) etc. PR

OC

ES

S IN

DU

ST

RIE

S

Thermal and Nuclear Energy: EDF , E.ON (Italy)

Mining: Cleveland Potash, PowerFuel (UK)

Offshore, Oil & Gas: MP Saipem (Eni Group) (Italy, Spain), Bourbon (Brazil)

Training made for EDF (France), Electrabel (Belgium), GDF Suez (France), Hinkley Point (UK),

Belkalyi Mines (Bielorussia), P&H Mine Pro – Joy Global (USA), Coal of India Ltd (India) etc.

CO

NV

EN

TIO

NA

L

EN

ER

GY

Wind Energy: Maia Eolis, Vestas, REpower, Gamesa, La Compagnie du Vent, GE Energy, Enel Green Power

Hydro: EDF (France), Santo Antônio, Jirau, Electronorte (Brazil), Cahora Bassa (Mozambique), EdiPower,

Enel Green Power (Italy)

Training made for REpower (France, Germany, USA), GE Energy (USA), Suzlon (USA),

Gamesa (Germany, USA), Iberdrola (USA), VOITH (Germany), Enertrag (Germany), E-On (Germany),

Hydro Quebec (Canada), Noble Power (USA), Next Era Energy (USA), GE Power & Water (USA), National

Hydro (NHPC) (India) etc.

RE

NE

WA

BL

E

EN

ER

GY

• 16 / 23

• 17 / 23

Diagnostics Form (1/2):

In Situ Machining of Motors or Generators

Information required before the intervention:

Subject of the intervention: Motor Generator

Machine:

Machine manufacturer:

Machine type:

Generator: DC AC

Motor: DC AC

Horizontal Vertical

Slip Ring Assemblies:

Number of rings:

Material: Steel (Alloys) Bronze

Diameter (mm):

Ring width (mm):

Helical groove: with without

Depth of the helical groove (mm):

Access to the machine:

Access door dimensions: Width (cm) ________ x Height (cm) ________

Distance between rotor and door (cm):

Comments:

Customer:

Name:

Email:

Telephone:

Address:

GPS coordinates:

Please send us pictures of the Commutator or Slip Ring assemblies, their nameplate,

environment, conditions etc.

DC Machine

Armature Voltage (V)

Armature Current (A)

Field Voltage (V)

Field Current (A)

Mersen representative:

Name:

Email:

Telephone:

Commutator:

Diameter (mm):

Width (mm):

Nr of bars:

Mica width (mm):

Nominal Speed (rpm)

Power (kW) AC Machine

Stator Voltage (V)

Stator Current (A)

Rotor Voltage (V)

Rotor Current (A)

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

• 18 / 23

Brush-holder bolt:

Type: Square Circle

Number:

Diameter of the brush-holder bolt (mm):

Or section (mm):

Length of the brush-holder bolt (mm):

Distance between the centre of the brush-holder bolt and the commutator (mm):

Distance between two brush-holder bolts (mm):

Distance between the centre of the brush-holder bolt and the centre of the carbon brushes (mm):

Brush-holders:

Adjustment to be made: Yes No

Replacement to be made: Yes No

Carbon brushes:

Grade:

Dimensions (mm) t____ x a_____x r_____

Drawing reference:

Replacement to be made: Yes No

Motor power supply during the intervention:

By the customer By Mersen

If “by the customer”, please precise the method:

Auxiliary motor

Hydraulic, please precise the rotation speed (rpm):

Other (please precise):

Specific electrical motor inspection to be done:

Insulation measurement and control


Machine’s availability (provisional dates):

Machine’s condition:

Dust

Oil


Comments


In Situ Machining of Motors or Generators

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

• 19 / 23

Information required before the intervention:

Rings to be machined:

Power

Grounding

Method to take our tools to the nacelle:

Lifting device

Elevator


Comments

Customer:

Name:

Email:

Telephone:

Address:

GPS coordinates:

Type and model of the wind turbine:

Onshore

Offshore

Generator type:

Please send us pictures of Slip Ring assemblies, their environment, conditions etc.


Name:

Email:

Telephone:


Wind turbine: In Situ Machining of

Slip Ring Assemblies

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

• 20 / 23

Dimensions to be checked before the intervention:

1. Ring Diameter (mm):

2. Power Ring width (mm):

3. Grounding ring width (mm):

4. Distance between rings (mm):

5. Helical groove: with without

Depth of the helical groove (mm):

6. Ring material:

Stainless steel

Bronze

Other (please precise)

7. Diameter of insulated rod (mm):

8. Distance between insulated rod and slip ring (mm):

9. Length of insulated rod (mm):

Please precise if the measurement includes Power rings and/or Grounding ring

10. Distance between white insulated plates (mm):

11. Slip ring access dimensions: : Width (mm) ________ x Height (mm) ________

2

4

6

7

8

9

10

11

Width

Height

1

5 3


Wind turbine: In Situ Machining of

Slip Ring Assemblies

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

• 21 / 23

Survey (1/2):


Application:

Renewable Energy: Wind power Hydro power

Conventional Energy: Thermal & Nuclear power Mining Oil & Gas

Transportation: Railways Transit Aerospace Marine

Process Industries: Metallurgy Wire & Cable Paper Cement Other _____________ (please precise)

Test bench:

Slip ring assemblies Turbo generator Environmental chamber:

Testing objectives:

Test bench description:

Customer:

Name:

Email:

Telephone:

Address:


Name:

Email:

Telephone:

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Motor

Range of speed (rpm)

Slip ring assemblies

Quantity of slip rings

Material

Diameter (mm)

Width (mm)

Grooving pitch/groove (mm)

Slip ring assembly drawing number (please include the drawing to the

questionnaire)

Support slip rings

Quantity

Material

Electrical parameters

AC or DC current

Rated current (A)

Maximum current (A)

• 22 / 23

Survey (2/2):

Testing capabilities Test bench description:

Measurement parameters

Please precise the measurements to be done:

Method of recording :

Continuous recording

Item by item recording

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Ventilation system (if necessary)

Necessary airflow (m3/s)

Carbon brushes

Quantity

Grade

Tangential dimension (t), (mm)

Axial dimension (a), (mm)

Radial dimension (r), (mm)

Specific carbon brush pressure

(kPa)

Brush-holders

Quantity

Brush-holder drawing number (please include the drawing to the

questionnaire)

Environmental parameters

Temperature (C)

Humidity (RH)

Altitude (mbar)

Diagnostics

In situ commutator, slip ring and brush-holder refurbishment

Support services on a daily basis

Contact: [email protected]

www.mersen.com/en

A GLOBAL PLAYER

Mersen is a Global Expert in electrical specialties and graphite-based materials.

On-site service calls throughout the world

Commutation expertise

Measurements and diagnostics

Support services on a daily basis

Phone technical assistance

Technical literature on line of our site www.mersen.com or on request

([email protected])

Mersen provides training courses for maintenance of electric motors. For over 25

years, more than 3,000 technicians have been undergone training, either at our facility or

theirs.

AE

-Serv

ices-E

N-1

507

Mersen’s Services

Documents

NCE - Carbonevietnam.com.vncarbonevietnam.com.vn/pic/general/files/electrical...Vibration control Brush-holders pressure measurement, visual analysis and adaptation Complete machine